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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Carl Parker, Always curious Tibetans, Tibet, China

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Photo by Carl Parker,
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  #1  
Old 16 Aug 2013
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You still know more about this bike than anyone else
So,
Your tests indicate that the bike is charging when the lights are off but it is not charging when the electrical load is higher, with the headlight on.

As Jens says, maybe the RR is failing.

Answers nearly always generate more questions!

Do you have a wiring diagram for this bike?
How is the condition of the wiring loom?
Are all the earth/ground connections good?
Is the battery a known quantity - a good 'un?
Have you changed anything recently?
(An electrical fault might be the result of a particular single event or a gradual deterioration in the loom or a component).

Have a read through this thread for some ideas about fault finding:-
http://www.horizonsunlimited.com/hub...charging-67094
The beginning and the end are most relevant, unless your loom is as bad as the one discussed in that thread.

You need to be logical with mechanical problems and even more logical in faults of electrical circuits.
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  #2  
Old 17 Aug 2013
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It is relatively simple to do some resistance readings on the stator to check that it is ok. After that suspect rectifier/regulator. Use your manual to find the readings you should get.

You don't have supper bright headlight globes do you? Nor driving lights?
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  #3  
Old 17 Aug 2013
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Sounds like the regulator/rectifier is dying and cannot keep up with the load if the lights are on.

What is the charging voltage both with light off and light on, idle and higher speed. It should keep the voltage above 13.5 under load if working correctly and perhaps more.
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  #4  
Old 17 Aug 2013
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See above for the voltage readings. I will go through the Electrex fault finding found here....

http://www.electrosport.com/media/pd...ng-diagram.pdf

No big headlights, will whip the rack off and check RR earth etc under the tailpiece.

speak y'all Tuesday

Thanks
Min
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  #5  
Old 17 Aug 2013
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Quote:
Originally Posted by Walkabout View Post
even more logical in faults of electrical circuits.
Quote:
Originally Posted by theoneandonlymin View Post
It's hard to beat a flow chart for a dose of logic; nice find.
Enjoy!
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  #6  
Old 18 Aug 2013
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So I went to Page B after doing the START page and at the bottom of B where it says about the AC voltage out of the stator and three readings not being equal. Two of the readings were around the 70V level and one was 2V ! So what I am going to check next is the wiring closer to the stator to check for continuity to the three way block that goes to the RR.
Makes sense to me and is looking more like the stator according to the flow chart.

Min
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  #7  
Old 18 Aug 2013
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Yep,if you lose one of the 3 phases, you are at 2/3's capacity. Good find. I hope you find a wire problem and not the actual stator...
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  #8  
Old 21 Aug 2013
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Quote:
Originally Posted by Walkabout View Post
S
Do you have a wiring diagram for this bike?
I guess I should have asked, also, do you have a workshop manual?

I've had the side cover off the generator of a TTR600 (it has the same engine, more or less) but I didn't change the stator.
What I do remember is:-
1. There is oil in there - I think I tipped the bike over on its' side to stop it running out, but I may have drained it (someone else can add to this point).
2. I definitely got a new paper gasket for that cover on the basis that they are one-use only and it is a PITA to put it all back together to then find that there is oil leaking/weeping.
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Old 21 Aug 2013
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Don't forget it MAY be a simple knackered battery!

I had exactly the same problem with one of mine - went through the obvious (alternator, coil, reg, etc) above and problem still present.

The nearly new battery was fading under load.

Replaced it with a better German battery and problem sorted.
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  #10  
Old 22 Aug 2013
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I have the pdf manual thanks.
Drain oil, remove cover, remove stator bish bash bosh job done . When the gasket arrives.
Bad battery would not give the dodgy resistance readings across the stator.
I can put my gazebo up in the back yard for a bit of cover . that's what I bought it for. 8 foot wide yard. 8 foot wide gazebo with fence walls !!

Let you know the results next week.

Min
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  #11  
Old 22 Aug 2013
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yes, it's the stator..

1-Put the bike on it's side remove the small e-start motor cover as there is ONE bolt in there that you need to take out and can only access from there!

2-Remove the stator coveruse a screwdriver that fits perfectly on the bolts or you will strip them!

3-If the gasket is damaged, replace it with a new one! I also used a very thin layer of liquidgasket on both engine part and stator cover!
If you put some on the engine part, it will hold the new gasket perfectly in place when you put the stator cover back on!

4- When you're putting the stator cover back on, be careful not to crush the neutral cable between the engine part and the stator cover!

Keep in mind that the regulator/rectifier might also be faulty, so check it out!
And the battery is probably wasted aswell.... get an AGM battery or one of those Li-on/Lipo whatever batteries: Lithium Ionen Batterie Yamaha XT 600 E '90 '03 HJTX9 FP | eBay

Vando
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  #12  
Old 31 Aug 2013
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Grrrrrrrrrrr
A few days later than anticipated but wish that I had a chance last week.
Drain oil , cover off , remove stator, clipped the wires to aid removal . The screw holding the wire shield was that tight the head sheared off ! Never mind.
Put the old rotor beside the new. Wrong size !!!!
New stator : 115mmx54mm
Old stator : 103mm x 42mm
Of course Electrex is shut for the weekend.
This one is the same size ;
Electrex World - Motorcycle electrical parts for Japanese, European & British bikes | Electrex World Ltd G73
Is this correct or do I wait for them to tell me on Monday???
I was sent a G45 .
At least I have a few spare days to sort it.

Secondly when I took the cover off there was an O ring loose inside the flywheel. Not mashed up. There was one on the cover as well where it should be. Where did it come from ?

Min
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  #13  
Old 31 Aug 2013
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Im pretty sure the boltholes for the xtz660 doesnt match the xt600

I seem to recall I had both a xt600 and a xtz660 stator on my table at the same time, they looked very simular, but wasnt identical.

The xtz660 would be awesome though, theyre about 280W.
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  #14  
Old 1 Sep 2013
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Quote:
Originally Posted by theoneandonlymin View Post
Put the old rotor beside the new. Wrong size !!!!
Min
This reminds me of an old saying in woodwork/joinery: - measure twice, cut once.

Never mind, progress consists of two steps forward and one backward, per day.
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  #15  
Old 1 Sep 2013
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Wemoto.com seem to sell the G73 for the XT . 103x42x16

Does this definitely mean that when I speak to Electrex tomorrow it is definitely what I need ?

Min
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